Structural hybrid attachment system and method

Abstract

An integrated structural system for a vehicle is provided. The integrated structural system includes a molded duct system configured to guide airflow having a first section and a second section and configured to operably attach a vehicle component thereto. The integrated structural system also includes a metal structure integrated with the molded duct system by means for integrating the metal structure with the molded duct system forming an integrated structural load path assembly. The integrated structural load path assembly is configured as a load bearing area to distribute a load of the vehicle component operably attached thereto. The means for integrating the metal structure with said molded duct system include, but not limited to, at least one of, sonic welding, heat staking, insert molding, and gluing.

1. An integrated structural system for a vehicle, comprising:
 a molded duct system configured to guide airflow, said molded duct system having a first section having a first flange portion and a second section having a second flange portion, said molded duct system configured to operably attach a vehicle component thereto; and 
 a metal structure, said metal structure integrated with said molded duct system by a means for integrating said metal structure with said molded duct system forming an integrated structural load path assembly, said integrated structural load path assembly being configured as a load bearing area to distribute a load of said vehicle component operably attached thereto over said integrated structural load path assembly, wherein said means for integrating said metal structure with said molded duct system includes joining said first flange portion and said second flange portion by one of; 
 sonic welding, 
 heat staking, 
 insert molding, and 
 gluing. 
 
   
   
     2. The integrated structural system of  claim 1 , wherein said integrated structural load path assembly is a cross car structural beam having a vehicle HVAC air duct assembly. 
   
   
     3. The integrated structural system of  claim 1 , wherein said vehicle component is one of:
 a steering column; and 
 an HVAC assembly. 
 
   
   
     4. The system integrated structural of  claim 1 , wherein said metal structure is at least one of:
 a metal tube; and 
 a metal frame member. 
 
   
   
     5. The integrated structural system of  claim 1 , wherein said metal structure is fabricated by one of stamping, bending, hydroforming, extruding and casting. 
   
   
     6. The integrated structural system of  claim 1 , wherein said metal structure includes one of steel, aluminum, and magnesium. 
   
   
     7. The integrated structural system of  claim 2 , wherein said metal structure extends a length of said cross car beam structure. 
   
   
     8. The integrated structural system of  claim 7 , wherein said metal structure includes brackets at opposing ends thereof for mounting said integrated structural load path assembly to the vehicle. 
   
   
     9. The integrated structural system of  claim 1 , wherein when said means for integrating said metal structure with said molded duct system includes insert molding, said insert molding includes at least one of:
 compression molding; and 
 injection molding. 
 
   
   
     10. The integrated structural system of  claim 9 , wherein said compression molding includes extrusion deposition compression molding (EDCM). 
   
   
     11. The integrated structural system of  claim 1 , wherein said means for integration further includes a protrusion extending from at least one of said first section and said second section toward said metal structure encased therebetween. 
   
   
     12. The integrated structural system of  claim 11 , wherein said protrusion extends into one of a cavity and an aperture configured in said metal structure. 
   
   
     13. The integrated structural system of  claim 12 , wherein said protrusion extends to an opposing section of said molded duct system. 
   
   
     14. The integrated structural system of  claim 1 , wherein said metal structure includes a portion extending therefrom configured to receive a mechanical fastener extending through one of said first and second flange portions. 
   
   
     15. The integrated structural system of  claim 1 , wherein said molded duct assembly is configured to provide air to an internal compartment of the vehicle. 
   
   
     16. The integrated structural system of  claim 1 , wherein said first and second sections of said molded duct assembly is composed of a plastic. 
   
   
     17. The integrated structural system of  claim 1 , wherein said first and second sections form a one-piece structure, wherein said first and second sections define portions of said one-piece structure integrated with said metal structure.